Thermoset polyurethane matrix fiber reinforced composite

Abstract

A composite fiber and resin reinforcement for strength members for use in the composite wood industry. The composite fiber and resin reinforcement is a fiber reinforced polymer (FRP) composite comprising a thermoset polyurethane resin matrix and a plurality of fibers. Typical uses will be as a reinforcing material for wood laminates, such as wood support beams (glulam), truck floors and truss fabrication.

1. A reinforcing material for wood or wood-based products for increasing the useful strength of wood or for reducing the thickness, grade or weight of the wood or wood-based products without reducing the load bearing value of comparable conventional wood or wood-based products, said reinforcing material comprising:
 a fiber-reinforced composite material comprising a plurality of fibers impregnated with a resin matrix, wherein the plurality of fibers are predominantly unidirectional reinforcing fibers aligned along the longitudinal dimension of the reinforcing material and said resin matrix comprises a thermoset polyurethane resin, 
 wherein a ratio of said plurality of fibers to the resin matrix is from about 50% to about 70% by volume. 
 
     
     
       2. A reinforcing material according to  claim 1  further comprising:
 a first pair of generally opposed sides parallel to each other and a second pair of generally opposed sides parallel to each other, said two sets of sides enclosing an internal section comprising said thermoset polyurethane resin matrix and said plurality of reinforcing fibers, said first set of sides having a width greater than the width of said second set of sides, said first set of sides and said second set of sides forming an elongated flat structure. 
 
     
     
       3. A reinforcing material according to  claim 2  wherein said elongated flat structure is selected from the group consisting of a web, a plate and a plank. 
     
     
       4. A reinforcing material according to  claim 1  wherein said matrix further comprises at least one resin selected from the group consisting of thermoset phenolic resin, thermoset polyester resin, thermoset epoxy resin, thermoset vinyl ester resin, thermoset resorcinol, thermoset melamine resin and thermoset acrylic resin. 
     
     
       5. A reinforcing material according to  claim 1 , wherein at least a part of said plurality of fibers are selected from the group consisting of aramid fibers, polyethylene, nylon, polyester, ceramic, fiberglass, carbon and basalt. 
     
     
       6. A reinforcing material according to  claim 1  having an overall thickness of no greater than 0.035 inches. 
     
     
       7. A reinforcing material according to  claim 1  having an overall thickness of no greater than 0.060 inches. 
     
     
       8. A reinforcing material according to  claim 1 , further comprising a veil for increasing cross-wide strength during handling of said reinforcing material, said veil comprising a plurality of random, woven, sewn or swirled reinforcing fibers. 
     
     
       9. A reinforcing material according to  claim 8  wherein said veil comprises nylon, polyester, or other thermoplastic materials. 
     
     
       10. A reinforcing material according to  claim 8  wherein said veil has a thickness of between 0.010 inches and 0.050 inches. 
     
     
       11. A reinforcing material according to  claim 1  wherein said thermoset polyurethane resin matrix further comprises a one or two-part polyurethane resin. 
     
     
       12. A reinforcing material according to  claim 1  wherein said thermoset polyurethane resin matrix further comprises between 5% and 25% filler. 
     
     
       13. A reinforcing material according to  claim 1 , wherein the ratio of said plurality of fibers to the polymeric resin matrix is 60-65% by volume. 
     
     
       14. A wood composite comprising;
 at least one wooden member having two surfaces disposed in substantially parallel relation to one another; and 
 at least one reinforcing material disposed at a predetermined location adjacent said at least one wooden member, said at least one single-layered reinforcing material comprising:
 a first pair of generally opposed sides parallel to each other and a second pair of generally opposed sides parallel to each other, said two sets of sides enclosing an internal section comprising a thermoset polyurethane resin matrix and a plurality of reinforcing fibers, said first set of sides having a width greater than the width of said second set of sides, said first set of sides and said second set of sides forming an elongated flat structure, 
 wherein a ratio of said plurality of fibers to the resin matrix is from about 50% to about 70% by volume. 
 
 
     
     
       15. A wood composite according to  claim 14  wherein said elongated flat structure is selected from the group consisting of a web, a plate and a plank.